疲劳寿命计的电阻变化特性研究

疲劳寿命计的电阻变化量与所加交变应变量和循环数呈增函数关系，其变化机理复杂，具有一定的分散特性。通过实验，可知其分散性与电阻变化量有直接和内在的关系。经实验数据的拟合可得到此曲线函数，由此函数得出的电阻变化的分散特征值与实验值吻合。通过此函数关系可计算任意电阻变化量的分散性，进一步求得实验值的可靠性。     

热交变载荷下10%Cr耐热钢蠕变疲劳裂纹萌生特征

为调节新能源间歇式发电模式所带来的弊端,需要使用火力发电厂调峰稳定电网波动。调峰过程中机组频繁启停,加剧高温部件的疲劳蠕变损伤。通过分析现有寿命模型描述温度交变载荷下汽轮机转子钢性能的不足,提出预载荷实验方案。且以预载荷实验数据为基础,优化现有寿命预测模型。通过模拟交变温度下的临近工况实验,对比应力应变关系和疲劳蠕变寿命,对所优化的寿命模型进行了评估。     

疲劳寿命计电阻变化的灰色建模研究

疲劳寿命计具有电阻-疲劳记忆特性，是一种新型的无损检测元件。其电阻值随疲劳而增加，载荷卸除后电阻变化值保留。它可用于多种目的的疲劳测试和结构疲劳检测。在给定载荷下，循环数和电阻变化量具有本征性的灰色关系，运用灰色系统的理论和方法，通过对循环数数列的一次累加，生成一个光滑离散函数。据此建立GM模型，并求解灰色系统微分方程。运用还原模型，可由测得的电阻变化量计算循环次数，进而推算结构的剩余寿命。     

交变载荷对CFRP复合材料-铝合金粘接接头剩余强度的影响

为了给碳纤维增强聚合物（CFRP）复合材料粘接结构的安全设计及应用提供参考,针对CFRP复合材料-铝合金对接接头,研究了拉-拉交变载荷作用下的疲劳寿命特性及剩余强度变化规律。设计专用夹具,完成接头的制作及固化,并测试其拉伸、剪切准静态失效强度,在此基础上进行不同载荷水平下的疲劳寿命测试。选取特定载荷水平,测试不同循环次数后的接头剩余强度,并对失效形式进行观察分析。结果表明:CFRP复合材料-铝合金对接接头强度-寿命（S-N）曲线在单对数坐标上符合线性函数规律;随着交变载荷循环周期的增加,接头剩余强度呈先慢后快的下降趋势,而且在较大的载荷水平下,下降幅度更为明显;经历交变载荷循环前、后接头失效形式发生改变,由局部CFRP复合材料表层撕裂转变为局部界面破坏。结合试验测试所获得的初始失效准则,并引入疲劳退化因子,建立内聚力模型对交变载荷作用下的粘接接头强度衰减进行数值模拟,结果表明所建立模型能够有效预测交变载荷作用下的接头剩余强度。      

疲劳损伤钢件修复的最佳时机

为了研究影响疲劳损伤中间退火修复效果的诸因素,找出最佳修复时机的变化规律,在不同的恒应变控制下,对40Cr调质钢进行疲劳循环加载,求得存活率为90%时的寿命Nf.将试样疲劳加载到少于Nf的不同周次后,再进行中间退火修复.发现中间退火可以延长损伤件的疲劳寿命.本次试验条件下能使疲劳寿命提高到原始试样的二倍.修复效果与损伤周次和承受的循环应变大小有关.用高灵敏度电阻仪和TEM对疲劳损伤过程和修复后材料的微观结构进行了测试和观察.发现中间退火不能使损伤的材料恢复到原始材料状态.疲劳加载对材料的微观变化有两个相反的影响:疲劳损伤导致形成微观裂纹,但疲劳加载在材料中累积的应变能在中间退火过程中,作为附加驱动力,促使材料更加均匀、稳定,从而减少了形成微裂纹的条件.当循环应变增加,获得最佳修复效果的损伤周次减少.     

数字疲劳传感器的设计及应用

为了解决疲劳传感器在结构疲劳监测时模拟信号传输噪声大、热输出大等引起的监测精度不高的问题,研究了一种数字疲劳传感器,此传感器采用片上系统ADuC845完成数据的采集与处理,传感器自带稳压,高精度、低温漂供桥与参考电路。传感器实现温度补偿、非线性修正及数字信号传输。并根据桥梁载荷谱的瑞利分布特点,得到该分布下的疲劳响应计算方法。采用倍增器的双疲劳计结构设计,利用疲劳计响应的非线性特性,得到疲劳传感器电阻变化与桥梁瑞利载荷谱的对应关系。     

汽轮机转子10%Cr钢的高温低周疲劳特性

在分别控制应变和温度的条件下进行超超临界汽轮机转子10%Cr钢的高温低周疲劳实验,用SEM和TEM分析了10%Cr钢实验前后的表面形貌和亚晶粒结构。根据实验数据拟合应力-应变曲线、应力-寿命曲线和应变-寿命曲线,得到了反映材料高温低周疲劳特性的Ramberg-Osgood参数和Manson-Coffin参数。对比分析了低周疲劳实验初始和结束两个阶段的滞回曲线和应力-寿命曲线,并讨论了不同温度和不同应变幅控制的塑性应变。结果表明,在高温工况下10%Cr钢的塑性应变较为明显,随着应变幅的增大钢的疲劳寿命降低,随着循环周期的变化塑性应变速率经历了下降-过渡-上升三个阶段,曲线出现拐点。最大裂纹长度随循环周期呈非线性扩展,高温低周疲劳载荷使钢中的亚晶粒尺寸增大。     

基于疲劳寿命计的桥梁载荷谱识别研究

疲劳寿命计是结构承载过程中理想的疲劳状态监测元件，其电阻产生的不可逆变化反映了结构的疲劳加载历程。首先比较分析了普通应变片和疲劳寿命计在实际应用中的优劣，然后在采用恒幅加载实验研究其基本测试性能的基础上，通过多级加载实验进一步证实了疲劳寿命计电阻响应规律的正确性，由此研究分析了桥梁等大型结构在实际的瑞利分布载荷作用下的疲劳加载历程，并对其使用寿命和剩余寿命进行预测。     

基于疲劳寿命计的疲劳状态诊断方法研究

结构的疲劳状态诊断是指在疲劳载荷作用过程中，在结构丧失承载能力之前，对结构的损伤和承载性能的变化的检验和评估。利用自行研制的疲劳寿命计作为传感元件，对某结构进行了疲劳损伤状态的诊断的研究。研究结果表明，疲劳寿命计在疲劳载荷的作用过程中产生稳定的电阻变化，可以通过该电阻变化表示疲劳进程，并以此建立等幅加载和非等幅加载条件下的对应关系，诊断其疲劳状态。     

细晶化和余热处理抗震钢筋的高应变低周疲劳行为分析

基于钢筋混凝土中钢筋在地震交变载荷下的失效模型,采用恒应变控制方式,室温下对细晶化和余热处理两种生产工艺得到的400MPa级抗震钢筋的高应变低周疲劳性能进行了研究。疲劳寿命数据用双参数威布尔统计方程处理后采用Coffin-Manson和Hollomon公式拟合。为了计算地震载荷下钢筋的能量吸收率,建立一个新的预测模型并命名为循环韧度。结果表明,相对于余热处理钢筋,细晶钢筋具有更高的循环韧度、低周疲劳寿命,以及疲劳过渡寿命。余热处理钢筋在±1%应变幅以上加速循环软化,这是由于其表层回火马氏体中二次裂纹在循环载荷下萌生并快速扩展造成的。细晶钢筋循环塑性应变均匀,裂纹开裂几率小,具有较好的高应变低周疲劳性能。     

疲劳状态检测元件的研究

疲劳状态检测元件对于检测在役的结构和构件的疲劳损伤状态具有独特的优势。对该元件的机理、工艺和性能进行了进一步的研究。采用四种箔材及两种制片工艺研制了疲劳状态检测元件，并对其性能进行了试验研究。实验结果表明，疲劳状态检测元件的阻值能够根据累积循环应变历程产生相应的变化。采用工艺1的疲劳状态检测元件的最大电阻变化率可达6．5％，而采用工艺2的最大电阻变化率为4．5％。研究结果表明，疲劳状态检测元件的制片工艺是影响其性能的主要原因。     

The effect of short range order on the thermal output and gage factor of Ni3FeCr strain gages

The ability of alloy 70Ni‐27.5Fe‐2.5Cr to form an ordered crystalline structure upon application of elevated temperature and the resulting effects on a variety of physical properties such as magnetism, strength, electrical resistance, and specific heat are well known. This paper demonstrates that strain gages made with 70Ni‐27.5Fe‐2.5Cr foil with an ordered crystalline structure have both high gage factors and high thermal outputs. The thermal output for strain gages made of 70Ni‐27.5Fe‐2.5Cr foil is demonstrated to be about 1,374 μΩ/Ω/K. The gage factor is nonlinear ranging in magnitude from about 5.0 to 3.6 for applied strains of 300 and 1,300 μE, respectively. The magnitude of gage factor and thermal output correspond with transformation of the crystalline structure from a state of disorder to a state of order. Comparisons to strain gages made with 36Ni‐57Fe‐7Cr foil are provided because of its use in the manufacturing of metal foil strain gages and their demonstrated high gage factors and high thermal outputs. Practical application for 70Ni‐27.5Fe‐2.5Cr strain gages is demonstrated by dead‐weight loading of shear‐beam load cells at low applied strain levels to minimise the effect of nonlinear gage factor; and Wheatstone bridge cancellation of high thermal output.     

Fatigue testing of a composite propeller blade using fiber-optic strain sensors

The performance of surface-mounted extrinsic Fabry-Perot interferometric (EFPI) sensors during a seventeen-million-cycle, high-strain fatigue test is reported. Fiber-optic strain measurements did not degrade during the test. The sensors were applied to a composite propeller blade subject to a constant axial load and a cyclic bending load. Strain measurements were taken at four blade locations using two types of EFPI sensors and co-located electrical resistance strain gages. Static and dynamic strain measurements were taken daily during the 65 days of this standard propeller-blade test. All fiber-optic sensors survived the fatigue test while most of the resistive gages failed. The suitability of fiber-optic monitoring for fatigue testing and other high-cycle monitoring is demonstrated.     

Multiaxial creep–fatigue life prediction for cruciform specimen

This paper describes the high temperature multiaxial creep–fatigue life prediction for type 304 stainless steel. Finite element analyses were performed for determining the stress–strain state in the gage part of a cruciform specimen subjected to creep–fatigue loading under four strain waves at three principal strain ratios. Creep–fatigue lives of cruciform specimens were discussed in relation to the principal stress amplitude calculated by finite element analysis. Creep–fatigue damage was evaluated by linear damage rule and the suitability of three low cycle fatigue and three creep damage parameters was discussed.     

Fatigue assessment and fatigue life calculation of quenched and tempered SAE 4140 steel based on stress–strain hysteresis, temperature and electrical resistance measurements

In this paper, mechanical stress–strain-hysteresis, temperature and electrical resistance measurements are performed for the detailed characterization of the fatigue behaviour of quenched and tempered SAE 4140 steel used for many applications in the automotive industry. Stress-controlled load increase and constant amplitude tests (CATs) were carried out at ambient temperature on servo-hydraulic testing systems. The applied measurement methods depend on deformation-induced changes of the microstructure in the bulk material and represent the actual fatigue state. The plastic strain amplitude, the change in temperature and the change in electrical resistance can be equally used for an assessment of baseline fatigue properties in generalized cyclic deformation curves as well as in generalized Morrow and Coffin–Manson curves. On the basis of comprehensive experimental fatigue data, the physically based fatigue life calculation method ‘PHYBAL’ based on the generalized Basquin equation was developed. S–N (Woehler) curves calculated with ‘PHYBAL’ using data from only three fatigue tests agree very well with the conventionally determined ones.     

New fatigue life calculation method for quenched and tempered steel SAE 4140

In stress-controlled constant amplitude and service loading tests at ambient temperature mechanical stress-strain hysteresis, temperature and electrical resistance measurements were performed to characterize the fatigue behavior of the quenched and tempered steel SAE 4140. The applied measurement methods use deformation-induced changes of the microstructure in the bulk material and represent the actual fatigue state. A new test procedure combines any kind of load spectra with periodically inserted constant amplitude sequences to measure the plastic strain amplitude, the change in temperature and the change in electrical resistance at the same time. The average values of the measuring sequences are plotted as function of the number of cycles in cyclic ‘deformation’ curves and represent the summation of microstructural changes caused by service loading. On the basis of generalized Morrow and Basquin equations the physically based fatigue life calculation method “PHYBAL” was developed for constant amplitude and service loading. With only three fatigue tests, Woehler (S–N) and fatigue life curves can be calculated in very good agreement with experimental ones determined in a conventional manner. The application of “PHYBAL” provides an enormous saving of experimental time and costs.     

应变反馈式压电陶瓷微位移驱动器的研制

介绍了采用应变片测量压电陶瓷微位移驱动器位移的原理和设计思想,介绍了实验装置的结构,给出了实验结果,证明将应变片直接粘贴在压电陶瓷基体表面测量其位移的方法是可行性的;通过对压电陶瓷滞回特性的测定,提出了建立压电陶瓷的控制模型的基本思路。     

Remaining Life Evaluation Based on Strain Deformation Monitoring

The operating conditions of a power plant affect its structural integrity due to many degradation mechanisms, among which is creep. Strain measurements constitute a relatively simple and reliable method of obtaining accurate data regarding the capability of engineering materials to withstand loads and of determining stress distribution in all manner of structural components. This work carried out a critical evaluation of the application of a high-temperature strain gage on a strain and stress analysis. The sensor was undergoing a group of long-term creep tests whose results were compared with the creep machine’s acquisition system. The same strain gage was part of a monitoring system and its out some used on the remaining life evaluation a power plant’s pipeline. The methodology consists of online strain monitoring of those components or regions more susceptible to creep failure, which were identified by finite element analysis. The long-term creep tests using high-temperature strain gages showed that the relative position between sensor and the sample necking region exercises great influence on the measured results. Linear relationship between minimum creep rate obtained by strain gages and rupture time values was observed. The power plant pipeline analysis showed that thermomechanical fatigue is the predominant degradation mechanism.